WO2010134057A1 - Electrically isolated heat dissipating junction box - Google Patents

Electrically isolated heat dissipating junction box Download PDF

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Publication number
WO2010134057A1
WO2010134057A1 PCT/IB2010/052287 IB2010052287W WO2010134057A1 WO 2010134057 A1 WO2010134057 A1 WO 2010134057A1 IB 2010052287 W IB2010052287 W IB 2010052287W WO 2010134057 A1 WO2010134057 A1 WO 2010134057A1
Authority
WO
WIPO (PCT)
Prior art keywords
junction box
chamber
heat sink
circuit board
photovoltaic panel
Prior art date
Application number
PCT/IB2010/052287
Other languages
English (en)
French (fr)
Inventor
Guy Sella
Lior Handelsman
Vadim Shmukler
Meir Adest
Meir Gazit
Yoav Galin
Original Assignee
Solaredge Technologies Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Solaredge Technologies Ltd. filed Critical Solaredge Technologies Ltd.
Priority to JP2012511403A priority Critical patent/JP2012527767A/ja
Priority to EP20100727141 priority patent/EP2427915B1/de
Priority to CN201080021018.XA priority patent/CN102422429B/zh
Publication of WO2010134057A1 publication Critical patent/WO2010134057A1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • G—PHYSICS
    • G08—SIGNALLING
    • G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
    • G08B13/00—Burglar, theft or intruder alarms
    • G08B13/02—Mechanical actuation
    • G08B13/14—Mechanical actuation by lifting or attempted removal of hand-portable articles
    • G08B13/1409—Mechanical actuation by lifting or attempted removal of hand-portable articles for removal detection of electrical appliances by detecting their physical disconnection from an electrical system, e.g. using a switch incorporated in the plug connector
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions
    • H02G15/10—Cable junctions protected by boxes, e.g. by distribution, connection or junction boxes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • H02S40/345—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes with cooling means associated with the electrical connection means, e.g. cooling means associated with or applied to the junction box
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/02—Details
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H05K5/06—Hermetically-sealed casings
    • H05K5/062—Hermetically-sealed casings sealed by a material injected between a non-removable cover and a body, e.g. hardening in situ
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0007—Casings
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0007—Casings
    • H05K9/0009—Casings with provisions to reduce EMI leakage through the joining parts
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0007—Casings
    • H05K9/0015—Gaskets or seals
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S248/00—Supports
    • Y10S248/906—Electrical outlet box support
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing

Definitions

  • the present invention relates to a junction box for power sources, and specifically to a junction box for electrically connecting to a photovoltaic panel.
  • a photovoltaic module or photovoltaic panel is a packaged interconnected assembly of photovoltaic cells, also known as solar cells. Since a single photovoltaic module can only produce a limited amount of power, commercial installations include several modules or panels interconnected in serial and in parallel into a photovoltaic array. Electrical connections are made in series to achieve a desired output voltage and/or in parallel to provide a desired amount of current source capability.
  • a photovoltaic installation typically includes the array of photovoltaic modules, an inverter, batteries and interconnection wiring.
  • Electronic modules may be integrated with the photovoltaic modules which perform electrical conversion, e.g. direct current (DC) to direct current conversion, electrical inversion, e.g. micro-inverter, or other functions such as monitoring of performance and/or protection against theft.
  • electrical conversion e.g. direct current (DC) to direct current conversion
  • electrical inversion e.g. micro-inverter
  • US7291036 discloses a photovoltaic connection system including a connection box with for surface mounted diodes mounted on a printed circuit board inside of the connection box.
  • the connection box optionally includes a metal plate mounted inside the lid of the connection box as a heat sink for dissipating heat from the diodes.
  • clamp refers to a device used for the entry of electrical cables or cords into electrical equipment and is used to firmly secure an electrical cable entering a piece of electrical equipment.
  • in situ in the context of the present invention refers to bonding or attaching during manufacture, e.g. injection molding, of a part as opposed to attaching after manufacture of the part.
  • a junction box used for making electrical connections to a photovoltaic panel.
  • the junction box has two chambers including a first chamber and a second chamber and a wall common to and separating both chambers.
  • the wall may be adapted to have an electrical connection therethrough.
  • the two lids are adapted to seal respectively the two chambers.
  • the two lids are configured to be on opposite sides of the junction box relative to the photovoltaic panel.
  • the two lids may be attachable using different sealing processes.
  • One of the lids may be adapted to seal the first chamber and the other lid may seal the second chamber to a different level of hermeticity from that of the first chamber.
  • the first chamber may be adapted to receive a circuit board for electrical power conversion of the power output of the photovoltaic panel.
  • the junction box may include supports for mounting a printed circuit board in the first chamber.
  • the second chamber is configured for electrical connection to the photovoltaic panel.
  • the second chamber may optionally be configured to include diodes, e.g. bypass and/or blocking diodes.
  • the junction box may have electrical connection terminals mounted inside the second chamber for connecting a circuit to the photovoltaic panel.
  • a metal heat sink may be bonded inside the first chamber.
  • the first chamber is adapted to receive a circuit board for electrical power conversion, and the metal heat sink is adapted to dissipate heat generated by the circuit board.
  • the heat sink is placed inside an injection mold during manufacture of the junction box.
  • the junction box may further include a pad adapted to provide thermal conduction and electrical insulation between the circuit board and the metal heat sink.
  • the metal heat sink may include a dovetail structure adapted to prevent mutual separation of the metal heat sink from the junction box.
  • the dovetail structure may be hollow.
  • a junction box used for making electrical connections to a photovoltaic panel.
  • the junction box has a metal heat sink bonded in situ inside the first chamber.
  • the first chamber is adapted to receive a circuit board for electrical power conversion, and the metal heat sink is adapted to dissipate heat generated by the circuit board.
  • the junction box optionally may have two chambers including a first chamber and a second chamber and a wall common to and separating both chambers. Two lids adapted to seal respectively the two chambers.
  • the metal heat sink may include a dovetail structure adapted to prevent mutual separation of the metal heat sink from the junction box. 19.
  • the wall may have an electrical connection therethrough
  • Figures IA and IB illustrate isometric views of a junction box, according to an embodiment of the present invention.
  • Figure 2A shows details of cross section of the junction box indicated by dotted line XX in Figure IA.
  • Figure 2B shows details of cross section YY of the junction box indicated by dotted line in Figure IA.
  • Figures 3A and 3B show isometric views of a heat sink according to another embodiment of the present invention.
  • junction boxes attached to the photovoltaic modules dissipate heat.
  • heat must be dissipated mostly through air inside the junction box.
  • metallic junction boxes When metallic junction boxes are used then heat may be dissipated directly through the junction box.
  • the use of a metallic junction boxes may be inconvenient because of regulations which require accessible metallic surfaces to be grounded and extra wiring is required.
  • Figures IA shows an isometric view 1OA of a junction box 12, according to an embodiment of the present invention.
  • Junction box 12 is shown mounted on the back (or non-photovoltaic side) 4 of a photovoltaic panel 16.
  • Junction box 12 has cable glands 130 which allow for termination of cables inside of junction box 12.
  • Junction box 12 has an outer casing 102 and an access into junction box 12 using a lid 106.
  • Figures IB shows an isometric view of the underside of junction box 12 detached from photovoltaic panel 16.
  • the isometric view shows glands 130 and two sections A and B of junction box 12.
  • chamber A is bounded by the dimensions Z x X with chamber A covered by lid 108.
  • Lid 108 gives access into chamber A of junction box 12.
  • Chamber B is an open section which is bounded by dimensions X x Y and shows terminals 104.
  • FIG. 110 is connected between terminals 104.
  • lid 106 removed to access chamber B and lid 108 used to access chamber A are on opposite sides of junction box 12.
  • Figure 2A shows details of cross section XX of junction box 12 indicated by dotted line in Figure IA, showing features of the present invention.
  • Cross section XX shows chamber sections A and B of junction box 12 mounted on non-photovoltaic side 4 of photovoltaic panel 16 with clips 216. The mechanical attachment between junction box 12 and photovoltaic panel 16 using clips 216 is such that junction box 12 is flat on photovoltaic panel 16 and a gasket may be used to seal the open end of chamber B.
  • Chamber A includes circuit board 260, thermally conductive pad 262, heat sink 264, outer casing 102 and lid 108.
  • Circuit board 260 is preferably mounted on supports adapted to receive circuit board 260.
  • Thermal pad 262 provides electrical isolation and thermal conductivity between heat sink 264 and circuit board 260.
  • the component side of circuit board 260 is preferably in contact with thermal pad 262 so that heat created by the components of circuit board 260 is dissipated by heat sink 264 via thermal pad 262.
  • Radio Frequency Interference (RFI) emission from junction box 12 as a result of the operation of circuit board 260 is reduced by having the side of lid 108 coated in an electrically conductive shielding 108a. Shielding 108a connects electrically to heat sink 264 to form a Faraday cage which suppresses RFI emission from junction box 12.
  • RFID Radio Frequency Interference
  • Lid 108 is preferably manufactured by an injection molding process. During the injection molding process of lid 207 a shield 108a may be placed placed in situ and bonded to lid 108 during the injection molding process. Thus, when lid 108 is attached to box chamber A ; junction box 12 is electrically isolated by heat sink 264 and shield 108a. Outer casing 102 and lid 108 additionally provide a non- electrically conductive isolation of heat sink 264 and shield 108a between the backside 4 of panel 16 and the exterior of junction box 12. Lid 108 is optionally permanently and/or hermetically sealed to chamber A. Chamber B includes terminal 104, support 214, bypass diode 110, lid 106, bus bar 212 and wall 202.
  • Wall 202 provides physical separation between chambers sections A and B. Electrical connectivity between circuit board 260 in chamber A and electrical connector 104 in chamber B is via bus bar 212. Bus bar 212 is sealed in wall 202 in such a way as to preserve the desired hermeticity of chamber A for example against the ingress of water or humidity. Both electrical connector 104 and bus bar 212 are supported mechanically by support 214. Support 214 may also provide hermetic sealing and/or electrical isolation between one end of connector 104 which connects to bus bar 212 and the other end of connector 104 which connects to connections provided by photovoltaic panel 16. Bypass diode 110 connected to connector 104 may be located between support 214 or backside 4 of panel 16 or between support 214 and lid 106.
  • Lid 106 gives access to chamber B whilst junction box 12 is physically attached photovoltaic panel 16 but electrically isolated from panel 16.
  • a preferred mechanism of attaching lid 106 to junction box 12 is to use a rubber gasket arrangement such that chamber B is hermetically sealed against for example the ingress of water/ humidity through lid 106 into chamber B.
  • junction box 12 is constructed with a double wall 202 so that chamber A and chamber B are mutually separable and re- attachable. Similarly, connectors 212 are re-connectable between chamber A and chamber B. In this embodiment, a failure within the electronics of circuit board 260 may be repaired by replacing chamber A with a new circuit board 260 without requiring disconnection of chamber B from photovoltaic panel 16. Similarly, an electronics upgrade may be easily achieved.
  • Junction box 12 including casing 102, lids 108/ 106, heat sink 264, and thermal pad 262 are preferably adapted to comply with temperature and insulation standard of IEC 61215 (Ed. 2) or other applicable industry standards for use with connection to photovoltaic panels.
  • Junction box 12 and lids 108/ 106 may be manufactured by injection molding of acrylonitrile butadiene styrene (ABS) thermoplastic, Polybutylene terephthalate (PBT), Poly(p-phenylene oxide) (PPO) or a thermoset such as epoxy resin.
  • ABS acrylonitrile butadiene styrene
  • PBT Polybutylene terephthalate
  • PPO Poly(p-phenylene oxide)
  • thermoset such as epoxy resin.
  • Figure 2B shows details of cross section YY of junction box 12 indicated by dotted line in Figure IA, according to an embodiment of the present invention.
  • Cross section YY is of chamber A mounted on backside 4 of photovoltaic panel 16.
  • Cross section YY shows outer casing 102, heat sink 264 with dovetail structure 264, thermally conductive pad 262, circuit board 260 and lid 108 with electrical shield 108a.
  • the manufacture of box chamber sections A and B of junction box 12 in a preferred embodiment of the present invention is by an injection molding process.
  • heat sink 264 with or without dovetail 264a is placed inside box chamber A and is bonded in situ to box chamber A as a result of the injection molding process. Additional strength of the bonding between heat sink 264 and box chamber A may be provided by a dovetail structure 264a which may be an integral part of heat sink 264.
  • a further function of dovetail 264a ensures that the bonding between heat sink 264 and chamber A remains intact when for example junction box 12 is subjected to thermal stresses as a result of electronic components operating inside chamber A, high ambient heat and sunlight when junction box 12 attached to a photovoltaic panel.
  • dovetail structure 264a is typically increased in order to accommodate the size of the fastener.
  • a further feature of dovetail 264a is a hollow structure within dovetail 264a which allows for a deformation of dovetail 264a . The deformation of dovetail 264a allows for the different rates of thermal expansion of enclosure 102 and heat sink 264/ dovetail 264a during the curing/cooling of the bond between heat sink 264 and enclosure 102 of chamber A.
  • Heat sink 264 has four holes 302. Holes 302 are used to attach heat sink 264 into chamber A of junction box 12 using screws. The attachment of heat sink to chamber A may come as an additional step after the injection molding of junction box 12 or of a junction box 12 which is not injection molded. An additional thermal pad may be placed between heat sink 264 and enclosure 102 to ensure good contact between heat sink 264 and enclosure 102 after heat sink 264 is attached enclosure 102. The deformable nature of the thermal pad used to accommodate non-uniformity in surfaces of the heat sink 264 and enclosure 102 due to manufacturing tolerances of heat sink 264/ enclosure 102.
  • thermally conducting glue or potting material may be placed between heat sink 264 and enclosure 102.
  • the articles "a” “an” as used herein mean “one or more” such as “a heat-sink", "a circuit board” have the meaning of “one or more” that is “one or more heat-sinks” or “one or more circuit boards”.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Photovoltaic Devices (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
  • Connection Or Junction Boxes (AREA)
  • Casings For Electric Apparatus (AREA)
PCT/IB2010/052287 2009-05-22 2010-05-24 Electrically isolated heat dissipating junction box WO2010134057A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
JP2012511403A JP2012527767A (ja) 2009-05-22 2010-05-24 電気絶縁された熱放散接続箱
EP20100727141 EP2427915B1 (de) 2009-05-22 2010-05-24 Elektrisch isolierter hitzeabschwächender verbindungskasten
CN201080021018.XA CN102422429B (zh) 2009-05-22 2010-05-24 电隔离的散热接线盒

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US18045509P 2009-05-22 2009-05-22
US61/180,455 2009-05-22

Publications (1)

Publication Number Publication Date
WO2010134057A1 true WO2010134057A1 (en) 2010-11-25

Family

ID=42668129

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2010/052287 WO2010134057A1 (en) 2009-05-22 2010-05-24 Electrically isolated heat dissipating junction box

Country Status (5)

Country Link
US (10) US8476524B2 (de)
EP (3) EP2602832B1 (de)
JP (1) JP2012527767A (de)
CN (2) CN104158483B (de)
WO (1) WO2010134057A1 (de)

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US10599113B2 (en) 2016-03-03 2020-03-24 Solaredge Technologies Ltd. Apparatus and method for determining an order of power devices in power generation systems
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US20200313609A1 (en) 2020-10-01
CN104104329A (zh) 2014-10-15
EP2602831B1 (de) 2014-07-16
EP2602832B1 (de) 2014-07-16
US10686402B2 (en) 2020-06-16
US11695371B2 (en) 2023-07-04
EP2602831A1 (de) 2013-06-12
US10411644B2 (en) 2019-09-10
US20190348946A1 (en) 2019-11-14
EP2427915A1 (de) 2012-03-14
CN104158483B (zh) 2017-09-12
US20210175846A1 (en) 2021-06-10
US20160134234A1 (en) 2016-05-12
EP2427915B1 (de) 2013-09-11
EP2602832A1 (de) 2013-06-12
US9006569B2 (en) 2015-04-14
US20100294528A1 (en) 2010-11-25
US20150181738A1 (en) 2015-06-25
CN102422429A (zh) 2012-04-18
US20180069505A1 (en) 2018-03-08
CN102422429B (zh) 2014-08-06
US20130312995A1 (en) 2013-11-28
JP2012527767A (ja) 2012-11-08
US9748896B2 (en) 2017-08-29
US20230370019A1 (en) 2023-11-16
US20230044561A1 (en) 2023-02-09
US11509263B2 (en) 2022-11-22
CN104158483A (zh) 2014-11-19
US9748897B2 (en) 2017-08-29
US8476524B2 (en) 2013-07-02
US10879840B2 (en) 2020-12-29

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